Project:

Client:
AIR DISTRIBUTION SHEET METAL DUCT WORK
1.0 Scope: Supply, Installation, Testing, Commissio
ning &
Holding Performance Responsibility
1.1 Acceptable Manufactures: As per Approved
list of makes see Annexure.
1.2 Submittals for Review: a. Technical Data

1.3 STANDARD
2.0 SMACNA -2005 HHHHHH
IS 655 2006 II
IS 277-1997
TECHNICAL SPECIFICATION
SN. ITEM
1.0 Scope Scope of this section shall comprise of supply,assembly and inst
allation of Factory
fabricated sheet metal ducts as per approved shop drawings,speci
fications and Bill of
Quantities.Duct work shall include, all accessories like trans
verse joints,access doors,
splitters,vanes,hanging/ supporting arrangement ,tie rods,stiffn
ers as may be required to
make the system functional.In case of site fabricated ducts,the
scope of work shall also
include on site fabrication.
On award of work,the contractor shall prepare detail duct layout
shop drawings in relation
to site condition and co ordinate the same with latest architec
ture ,reflected ceiling plans
and other services.
The contractor shall also test and balance the entire air distri
bution system including every
air terminal as per approved shop drawing.
Duct design parameters Maximum Flow Velocity
450 MPM
Maximum Friction loss
6.5 mm WG/100 M
Maximum velocity at air outlet
150 MPM
Maximum Flow Velocity in exhaust duct 600
MPM
Duct material-Rigid Galvanised Steel,Cold rolled,low carbon,Lock for
ming quality,Grade D, Spangled, Plain
sheet.Zinc coating shall be of grade 120,having mass of coating
on both sides as 120 GSM
or class viii confirming to IS 277 - 1997. Mill test certificat
es shall be provided.In addition
if deemed necessary,the customers site engineer shall take sampl
es at random and get the
same tested for thickness and zinc coating at contractors expen
se.Alternatively, based on
application,the duct material can also be Aluminium,confirming
to IS 737. For exposed
 (not concealed) ducts those need finish painting,Galvanized, Zer
o spangled sheet shall be
considered.See BOQ.
For factory fabricated ducts,GSS /aluminium sheet raw material s
hall be used in coil form
only, to limit the longitudinal joints at opposite corner edge
s.However,for ducts those
are fabricated at site,discreet sheet may be used.
Fabrication and Installation SMACNA - 2005 for factory
fabricated ducts 250 Pa pressure rating
Standard IS 655 - 2006 for site,manual fabrica
ted ducts Low pressure duct
Unless otherwise specified,the duct PRESSURE CLASS shall be 250
Pa.However for duct
upstream of VAV box or HEPA filters, pressure rating shall be 5
00 Pa.

As per SMACNA 1.Each rectangular, rigid, duct piece length shall be, o
f minimum 1200 mm long.
2.Transverse duct joints shall be at 1200 mm c/c.
3.Transverse duct connector shall be 4 bolt, rolled on flange s
ystem.The flange
profile (TDF) shall be made out of duct sheet to minimise a
ir leakage and ensure
faster installation at site.
4.Longitudinal joint shall be pittsburgh type, located at diagon
ally opposite corners.
5.Transverse duct connector shall be complete in all respect inc
luding galvanised
corners,cleats,carriage bolts,flanged nuts and gasket.Gasket
shall be non toxic,
and of food grade quality.
6.The duct sheet panels shall have beads all around,at 300 mm
c/c, perpendicular
to air flow direction for rigidity as recommended in SMACNA
.
7.All duct work including straight sections,tapers, elbows etc s
hall be factory
fabricated.However,transformations collars and to suit piece
s only may be made
manually on site,as per site contraints.
8.Ducting shall be made using CNC plasma profile cutter,auto fol
der,roll former,
flanger and other related machines for dimensional accuracy
and consistent
quality.
9.All ducts shall have 4 Bolt transverse joints.Longitudinal pit
tsburgh seam shall
shall be located only on two opposite corners.The longitudin
al seam shall be
air tight. with smooth surface finish.
10.Ducts and accessories including insulation within ceiling spa
ces,visible from
air conditioned area shall be provided two coats of matt b
lack finish paint.
11.Changes in dimension and transformation shall be gradual with
aspect ratio adual,keeping aspect rat
io
preferably within 1:4,not exceeding 1:7.
12. Necessary air turns/vanes shall be provided in all elbows an
d bends with
devided fittings and collars.Branch connection shall be a
s per SMACNA.
13.All sheet metal plenum shall be factory fabricated,panel type
,and shall be
assembled at site.Plenum shall be fabricated from 18 G GI
sheet.The plenum t/16 G a
luminium
sheet.The plenum should be adequately reinforced and st
iffened with
25x25x3 mm angles as required.
14.To suit duct pieces fabricated manually at site, should have
4 bolt duct
connector. However,this shall be Slip on flanges,rolled from
GI section.To arrest
air leakage, the 4 Bolt system shall be with built sealan
t.These factory made
4 bolt flanges should be fixed to duct using pop rivets.
15.The flange shall be suitably sized to provide adequate streng
ht to duct.The duct
pieces should be adequately reinforced if necessary to ke
ep ducts true to shape
and prevent buckling and breathing.The sheet metal thickn
ess and 4 bolt TDF
rating shall be strictly as per Table detailed here under
.
16.The duct pieces shall be shipped to site un assembled,in two
L sections.Boxing
shall be done at site using electric seam closures or wood
en mallet.The duct
jointing of two corresponding pieces would mean tightening
of 4 nos carriage
bolts and installing cleats at no more than 150 mm from en
ds with spacing of
250 mm maximum.Requisite gasket should be properly provide
d between the
pieces.
17.To facilitate identification,all duct pieces shall have a par
t number,corresponding
to serial number assigned to it in measurement sheet.
18.For each drawing,all supply of duct work must be accompanied
by computer
generated detail bill of material indicating duct size,qua
ntity and piece length
with relation to part/serial number.
TABLE 1-rectangular DUCT PRESSURE RATING -250 Pa (Longi
tudinal seam - pittsburgh)
duct Duct Size sheet thickness piece length
Transverse joint Intermediate
mm (G) mm
reinforcement
GSS/AL
Rolled Form,TDF 600 c/c
upto 750 24/22 1200
 4 Bolt connector -
751-1000 24/22 1200
4 Bolt connector -
1001-1200 24/22 1200
4 Bolt connector -
1201-1500 22/20 1200
4 Bolt connector -
1501-1800 22/20 1200
4 Bolt connector -
1801-2100 20/18 1200
4 Bolt connector 25x25x3
2101-2700 18/16 1200
4 Bolt connector 50x50x3
TABLE 2 - rectangular DUCT PRESSURE RATING-500 Pa ( Longit
udinal Seam-Pittsburgh)
duct Duct Size Sheet thickness Piece
Length Transverse joint Intermediate
mm (G) mm
reinforcement
GSS/AL
Rolled Form,TDF 600 c/c
upto 700 24/22 1200
4 Bolt connector -
701-900 24/22 1200
4 Bolt connector -
901-1050 22/20 1200
4 Bolt connector -
1051-1250 20/18 1200
4 Bolt connector 25x25x3
1251-1500 20/18 1200
4 Bolt connector 25x25x3
1501-2150 20/18 1200
4 Bolt connector 50x50x3
Intermediate reinforcement as shown above in Table 1 & Table 2,
are MS angle
reinforcements ,to be provided on wider side of duct,attached wi
th the duct by
rivetting within 50 mm from duct corners and maximum 305 mm spac
ing between
rivets.
TABLE 3
Manual Fabrication of Duct Pressure Rating -500 Pa Longitu
dinal seam-Grooved corner lock seam
Duct at site-IS 655 Duct Size Sheet thickness Piece Lengt
h Transverse joint Intermediate
reinforcement
mm (G) mm
Slip On,TDC MS angles
0-600 24 2400 m
ax 4 Bolt connector -
601-750 24 2400
4 Bolt connector 25x25x3
751-1500 22 2400
4 Bolt connector 30x30x3
1501-2200 20 2400
4 Bolt connector 40x40x3
above 2200 18 2400
 4 Bolt connector 50x50x3

Material of fasteners All fasteners used in GSS duct work shall be gal
vanised or cadmium coated steel.
All MS angle if used for reinforcement shall be painted.
Transverse joint sealing All ducts with 500 Pa and above pressu
re rating ,shall be sealed at all transverse
joints namely,duct to duct,duct to branch and duct to collar tap
.In addition,the duct
which is upstream of VAV box shall be sealed.The sealant should
be water based,
solvent free,and should not contain chemicals, detrimental to he
alth namely,
silicone,asbestos,lead,mercury and mercury compounds and should
be non toxic.
This is in accordance to Seal class C of SMACNA 2005.
Leakage Testing After main duct with branches are installed,visually ins
pect for pin holes at corner,
transverse joints,cleat spacing,tapers etc for leakages.The inte
rnal of duct can be
illuminated using electric bulb,to check for light rays eminatin
g from duct joints to
take corrective action.This exercise needs to be done in parts m
eticulously, before
insulation.However for ducts with pressure rating of 75mm and ab
ove,air leakage
test of main duct should be done using test kit comprising of bl
ower with means
to vary flow rate,orifice plate and manometers.The applicable st
andard shall be
SMACNA -HVAC air leakage test manual.
Round ducting Rigid round duct shall be fabricated from Galvanised ste
el sheets,with specs stated
earlier.Alternatively.if stated in BOQ,Aluminium sheets will be
used.The ducts
shall be factory fabricated from GSS/Al sheet.Ducts shall be wit
h Spiral seam.
Contractor shall decide length of spiral seam duct considering j
ob layout,fittings
frequency,potential for damage during shipment,maneuverability e
tc.However,
duct length between joints shall not be more than 3000 mm.Duct t
o duct joint
shall be thro slip joint coupling/sleeve having groove in betwee
n.The mimimum
length of the coupling shall be 135mm.Pop rivets or screws must
be used to join
the duct with the slip coupling around the circumference at not
more than 200 mm
interval along the circumference.The slip coupling/sleeve shall
be made of atleast
same thickness of sheet as the duct.While the reducers/expanders
shall be plain
conical,the elbows shall be of segmented standing seam fabricate
d on high speed,
CNC plasma cutter,Gore locker etc.
 Thickness-Schedule
Duct Diameter Seam Type Sheet thickne
ss
75 to 250 mm Spiral
26 G
275 to 350 mm Spiral
24 G
375 to 600 mm Spiral
24 G
650 to 900 mm Spiral
22 G
Supporting arrangement All horizontal duct shall be independently suppo
rted from ceiling slab / structural
elements. The ducts shall be rigid and securely supported.Howeve
r the design
should facilitate level adjustment at site.The supporting trapez
e arrangement
should be approved type.The support trapeze to include M S angle
,Galvanised
threaded rod with nuts and washer.Dash fasteners/anchor fastener
s of adequate
loading capacity should be used for taking the supports.Sufficie
nt margin should
be available on either side of slotted channel/MS angle to accom
modate insulation
thickness.The threaded rod should have margin to make level adju
stment.The
MS angle, should be machine cut,ends chamfered,with holes drille
d.
Duct Size Trapeze size
Suspension rod dia support spacing Spacing
MS angle
upto 700 mm 25x25x3
8 mm 2400 mm
701 to 1000 mm 32x32x3
8 mm 2400 mm
1001 to 1500 mm 40x40x3
8 mm 2400 mm
1501 to 1800 mm 40x40x5
10 mm 2400 mm
1801 to 2250 mm 50x50x5
10 mm 2400 mm
2251 and above 50x50x5
12 mm 2400 mm
However at bends,equipment connection etc based on site conditio
ns, additional
support should be provided.Also two supports on either side of
flexible connection
shall be provided to prevent duct sagging.Self adhesive rubber
5 mm thick ,of 25
mm wide, shall be provided between duct insulation and duct supp
ort.
Vertical riser ducts should be supported at every floor level us
ing MS angle frame
fitted to the duct and resting on the floor slab as detailed in
SMACNA.
Round duct shall be supported using clevis hangers/Ring type sup
porting clamps.
The supporting clamps shall also be provided by duct manufacture
r.The clamp
shall be fabricated from minimum 30 mm wide 2.5 mm GSS flat,enci
rcling the duct
with nut and bolt on top,with suspension threaded rod of 8 mm di
a.Support spacing
shall be 2500 mm maximum.
Flexible ducts Where shown in drawings (see BOQ),flexible ducts shall b
e used for connecting
diffuser boxes.Flexible ducts shall have double lamination of me
ttalized polyester
film (aluminium sprayed on polyester),permanently bonded and re
inforced to a
coated, helix corrossion free steel wire.The duct shall be non
flammable with
Class 1 rating, as per ASTM E 84/BS 476 part 5/6.The duct shall
also be tear and
puncture resistant.Incase thermal insulation is required,the duc
t shall be wrapped
externally at factory with 25 mm thick ,16 kg/cum fibreglass,cov
ered with outer
jacket cum vapour barrier,made out of fibreglass reinforced mett
alized polyester
film.Flexible duct shall be supprted every 1200 mm to avoid sagg
ing, follow
manufacturers recommendation/SMACNA.

Access door Access doors shall be provided for all accessories fitte
d in ducts which require
frequent servicing and inspection.Doors shall be of atleast 450x
450 size.It should
be rigid and hinged type and shall be provided with air tight ga
sket.Insulated
ducts shall be with insulated doors preferably double skin, so a
s not to damage
the duct insulation every time the access door is opened.
Flexible connection All duct work connection to fans are to be provi
ded with flexible connection.This
will prevent transmission of vibration from moving machinery to
ducting system.
Flexible connection should also be provided across building expa
nsion joints.
Connection shall not exceed 200 mm in length,and shall be made f
rom fire and
moisture retardant double canvass.The connection shall be secur
ed to make
suitable air tight connection with duct.Thickness and strenght o
f flexible
connection shall be rated for duct operating pressure.
Volume control Dampers Volume control dampers shall be provided to faci
litate air balancing and isolation.
For proper air distribution,dampers should be provided at each d
uct branch take
offs those are located close to AHUs. Dampers are also required
for areas which
do not operate simultaneously for physical isolation. VCDs shoul
d also be installed at all
 at Fan and AHU outlets to provide a means of air balancing.Damp
er shall be louver
type in design,with opposed blade configuration.The damper shall
be complete
with suitable link,lever,quadrant and locing device and shall be
Box type in design.
Slip on, 4 Bolt flange connector shall be provided with duct dam
pers for joining
with duct.For sturdy design and limiting torque on blades,the da
mper blade length
shall be based on shorter side of duct.The damper casing shall
be of 18 G with
blades not less than 20G.The damper blades will be supported on
bronze bush.
Duct silencers Duct silencers/attenuators shall be installted wherever
asked for in the drawing
with performance parameters as shown in BOQ.
The duct attenuator shall be rectangular in shape, and of adequa
te length for
obtaining desired accoustical performance at 250 HZ.The duct ve
locity should be
less than 7 m/sec to keep the regenerative noise low.Inner liner
shall be accoustically transparent.
The outer casing shall be fabricated out of 22 G gavanised sheet
of minimum 120
GSM.The longitudinal seams shall be of pittsburgh type and air t
ight.Inner liner
shall be 22G GSS,perforated.Accoustic fill shall be inert,verm
in,moisture proof
and incombustible.It should be either fibreglass or mineral woo
l of 64kg/cum
density.The accoustic fill shall be filled under 10% compressio
n to eliminate voids
due to vibration.The design of pods/baffles shall result to sta
tic regain and shall
be aerodynamically efficient.Duct silencer shall be selected fo
r air pressure drop
of not more than 100 Pa.The accoutical performance of silencer
shall include
insertion loss at 250 HZ,Self generated noise power levels and
air pressure drop.
The size of silencer shall be same as duct size.The duct attenua
tor shall be
complete with suitable flanges for mounting with duct.

Installation During the construction,the contractor shall temporarily

close duct openings with
sheet metal covers to prevent debris entering the duct.
Great care should be taken to ensure that the duct work is insta
lled as per levels
indicated in drawing.After award of work the contractor shall vi
sit site,take
measurements and ensure that his shop drawings are prepared acc
ordingly so that
duct levels are maintained.
Where ducts pass thro brick partition wall,isolation barrier sho
uld be provided
between duct and opening.This can be using TF quality expanded
polystrene.
These are areas,where by design, return air is not supposed to,
be moving around
supply air duct.
All necessary allowances and provisions shall be made by the con
tractor for beams
and other services whether the same is shown in the drawing or n
ot.
Toilet exhaust ducts in case of guest rooms/patient rooms ,cabin
s in office areas
shall have gooseneck collars to avoid cross talk.
All ducts shall be totally free from vibration under all conditi
ons of operation,
whenever duct work are connected to fans,air handling units.Flex
ible connections
shall be provided. Duct support should be separate and independe
nt of ceiling
support.
MS/Al pop rivets with round heads inside shall be used.
All material for supporting arrangement including anchor fastene
rs shall be as
approved by consultant/architect/owner.
The contractor shall provide and erect duct as may be required t
o carry out the
intent of thesde specifications and drawings.The work shall meet
with the approval
of owners site representative in all its parts and details.
If a duct cannot be run as shown in the drawings,the contractor
shall install the duct
between the required points by any path available in accordance
with other
services and as per approval of owners representative.
All support angles,if of MS, shall be primer coated and finish p
ainted with black
matt finish air drying synthetic enamel paint.

Air Balancing Subsequent to commissioning of air distribution system,a

ir balancing should be
done following established practices in SMACNA and ASHRAE.Air fl
ow should be
measured at each outlet, and checked with design.The record of s
uch measurements
shall be documented AHU wise.The total air quantity of the unit
should be checked
along with Fan RPM.If necessary,corrective action need to be tak
en. The damper
quadrants should be locked.